Installation and Operating Instructions For ABSOLYTE® GP Batteries
Contents
1. 7 SECTION 8 8 0 System ASSeEmMDIY 7 8 1 Horizontal Single 7 8 1 1 B ttom Beam SUPPONS iien 7 8 1 2 E E 8 8 1 3 POONA SO N E 72 8 8 2 Horizontal Muliple Stacking AA a ADRAR 10 8 2 1 DIAG TE PITOS a E A 11 SECTION 9 0 9 1 9 2 9 3 9 4 9 5 9 6 9 7 9 8 9 9 9 10 SECTION 10 0 10 1 SECTION 11 0 11 1 SECTION 12 0 12 0 1 12 1 12 2 12 3 12 4 12 5 12 6 12 7 12 8 12 9 SECTION 13 0 13 1 13 2 SECTION 14 0 SECTION 15 0 SECTION 16 0 SECTION 17 0 SECTION 18 0 SECTION 19 0 SECTION 20 0 9 eee ee ee ee ee nee ee eee 12 BOSE I AU AU ON 12 CONNECTIONS System 12 5 12 Connections 5 12 Connections TOF QING 12 Connections SC 12 Connection CSI SIAN 12 E 12 EM E T E N E 12 Battery Nameplate2. No of CELLS CHARGER CURRENT SYSTEM VOLTAGE 102 103 105 106 108 109 110 111 112 115 116 117 118 119 120 N O O O T Ohmic 57 i Volts fie C Volts Figure 25 1 22 ADDITIONAL COMMENTS ABSOLYTE BATTERY MAINTENANCE REPORT DATE SERIAL NUMBER COMPANY ADDRESS GMB InpusTRIAL POWER BATTERY LOCATION NUMBER A Division of Exide Technologies INSTALL DATE CHARGER VOLTAGE cores MANUF DATE TEMPERATURE TYPE No of CELLS CHARGER CURRENT Ohmic SYSTEM VOLTAGE 111 112 115 116 117 118 119 120 6010241 2568288 5423 j basi bani buni bani ba gt C R I C R I mw a a el od 5 a SS SS Figure 25 2 283 ADDITIONAL COMMENTS Battery Temperature C Float Voltage at 25 C 2 23 2 24 3 235 4 235 235 5 234 2 35 6 234 235 7 N N N N A NIN NIN NIN APPENDIX A Temperature Corrected Float Voltages Expressed in Volts p
3. 20 15 RCO o E E 20 16 TAC OA sse cna ee ashes enor ace de cent 21 17 Temp rary Non US 21 18 21 19 CONNEC TON ae eon eee ne ee ee ee ene ees 21 20 AGI TS SUING 21 Page ON NNN 0 10 10 10 10 11 11 11 13 14 19 16 22 24 25 26 27 Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig 1A B 10 11 12A 12B 13 14 15 16 17A 17B 18 19A 19B 20A B 21 22 23 24 25 LIST OF ILLUSTRATIONS Typical Systems Top View Packed Modules Unpacking Modules Handling Lifting Strap Placement Typical Horizontal Stack Arrangements Front Views Typical Horizontal Stack Arrangements Back to Back and End to End Hardware Installation for 2 67 Wide Beam Support Hardware Installation for 4 5 Wide Support Completed Support to Module Installation Handling Module Base Support Assembly Tip Over Procedure Shackle Strap Usage Tip Over Procedure Module with Base Assembly After Tip Over Horizontal Stacking Shackle Strap Usage Handling and Stacking Horizontal Modules Hardware Installation Sequence Installing Hardware Completed Horizontal Stack Positio
4. heres 12 10 Protective Module COV C0 17 Module Cover Installation ates a 17 11 PANT NE E AE E 17 Constant Voltage 17 12 OSU NM 18 25 55 18 Floating Charge Method 18 Float Charge Float Voltages 18 18 T E E E T 18 Determining 5 18 Effects of Float Voltaga 19 Float Current and Thermal 19 AG TANS 19 Ohmic 19 13 Chago E E EEE S 19 Wl p Enia 19 Equalizing Charge WIG 20 14
5. Cell numerals should be applied to the top of the module and as close to the cell being identified as possible Suggest appli cation to cell restraint bars or to module channels Designate the positive terminal cell as 1 with succeeding cells in series in ascending order The system polarity labels should be applied next to the posi tive and negative terminals Apply pressure sensitive warning label provided on a promi nently visible module side or end The module cover is rec ommended 9 9 Warning Label 9 10 Battery Nameplate For future reference and warranty protection apply pressure sensitive nameplate on a prominently visible module Fill in date of installation and the specified capacity and rate Make sure surfaces are free of dirt and grease by wiping with clean dry wipers to ensure proper label adhesion For protective module cover installation see Section 10 AN Each module is provided with a transparent protective cover to help prevent accidental contact with live module electrical connections and to provide easy visual access to the system SECTION 10 10 0 Protective Module Covers When all system assembly has been completed as well as initial testing including initial charge and cell float voltage readings all covers should be installed Covers should remain in place at all times during normal operation of the battery system 10 1 Module Cover Installation Refer to Figure 24 for installatio
6. SECTION 92 61 2012 08 Installation and Operating Instructions For ABSOLYTE GP Batteries GNB UL Recognized Component NDUSTRIAL POWER Page SECTION 1 1 0 Gen ral 1 SECTION 2 2 0 SAN F COMMON E 1 2 1 Acid Electolyta BUMS 1 2 2 48 aes see 1 2 3 1 2 3 1 Static Discharge 5 1 2 4 2 2 5 important MESSAGE 2 SECTION 3 3 0 ares te a ee eae 2 3 1 Concealed Damage a EEEa eee 2 SECTION 4 4 0 Storage 2 4 1 1162219 SOC 2 4 2 Storage 2 SECTION 5 5 0 Installation 2 5 1 Space 2 5 2 Battery Location and Ambient Temperature 2 5 3
7. Same capacity cross sectional area cables connecting the positive and negative terminals of each string to the load or bus should be of the SAME LENGTH Choose the shortest cable length that will connect the battery string that is furthest from the load and cut all cables used to connect each string to the load to this same length 5 8 Stacking Limitations There are recommended limits on stacked battery configura tions Please refer to Appendix D for additional information NOTE Horizontal module arrangement only 5 9 Terminal Plates Each system is supplied with a terminal plate assembly for the positive and negative terminations These should always be used to provide proper connection to the operating equip ment and cell terminals Any attempt to connect load cables directly to cell terminal may compromise battery system per formance as well as the integrity of cell post seals 5 10 Grounding It is recommended that the modules or racks be grounded in accordance with NEC and or local codes See Appendix C for recommended procedure SECTION 6 6 0 Unpacking and Handling PACKED MODULES Figure 2 6 1 General Do not remove shipping materials if a storage period is planned unless charging is required per Section 4 2 The battery modules are generally packed in groups Lag bolts retain the modules to the shipping pallet together with a protective hood bolted in place Modules are also bolted together at
8. Time periods listed in Table B are for 77 F For other temperatures a compensation factor of 003 V F 0055 V C per cell is recommended The minimum voltage is 2 20 VPC temperature correction does not apply below this voltage TEMPERATURE CORRECTION V corrected V25 C T actual 25 C x 0055V C or V corrected V77 F actual 77 F x 003V F See Appendix A for standard values STEP 1 A Set constant voltage charger to maximum setting without exceeding 2 35 VPC Example For a target charge of 2 35 VPC 24 cell system you would set the charger voltage to 56 4 volts Depending on the battery s state of charge the charger may go into current limit at the beginning and decline slowly once the target charge voltage is reached Record time and current at regular intervals every hour as aminimum C Continue charging the battery until there is no further drop in charge current over 3 consecutive hours This could take days if the battery has been in storage for a long time D When the current has stabilized proceed to step 2 STEP 2 A Continue the charge for the time listed in Table B depending on the charger voltage setting The time is IN ADDITION to the time spent charging in Step 1 Example charge for 12 hours if the charger voltage is set to 2 35 VPC TABLE B INITIAL CHARGE 77 F CELL VOLTS TIME HRS Minimum 2 30 24 2 35 12 B Record cell voltages hourly duri
9. 24 2 35 12 Record cell voltages hourly during the last 3 hours of the charge time If after the charge time has completed but the lowest cell voltage has continued to rise you may extend the 20 charge monitoring cell voltages hourly until the lowest cell voltage ceases to rise C Proceed to Step 3 STEP 3 The Equalize charge is now complete Charger voltage can now be reduced to float voltage setting per Section 12 2 For a target float charge of 2 25 VPC on a 24 cell system you would set the charger voltage to 54 volts SECTION 14 14 0 Pilot Cell A pilot cell is selected in the series string to reflect the gen eral condition of cells in the battery The cell selected should be the lowest cell voltage in the series string following the initial charge See Section 11 0 Initial Charge Reading and recording pilot cell voltage monthly serves as an indicator of battery condition between scheduled overall individual cell readings SECTION 15 15 0 Records The following information must be recorded at installation and annually for every year of operation after installation These records must be maintained throughout the life of the battery and made available for review by GNB representatives for capacity or life related warranty claims Failure to collect and store these maintenance data will void the warranty Please review the warranty statement specific to the battery application for any additional require
10. BASE MODULE Figure 18 TYPICAL ASSEMBLY FOR BOTTOM MODULES HARDWARE AND SEQUENCE OF ASSEMBLY SAME AS 20B HORIZONTAL STACKS BACK TO BACK POSITIONING Figure 19A COMPLETED HORIZONTAL STACKS SIDE BY SIDE Figure 19B 8 2 1 Stack Tie Plate To achieve maximum stack stability especially where seismic conditions may exist as well as proper interfacing of inter stack connections metal tie plates are provided The plates used on stacks end to end are 3 x 1 x 1 8 with two 9 16 holes Use one tie plate at each interface on only the base and top modules of adjacent stacks See Figures 20A and 20B Position plates on the front and back channels and secure with hardware shown Where stacks have different levels install plates on shorter stack top module and adjacent mod ule Torque hardware to 47 Newton meters 35 Ft Lbs This completes the mechanical assembly of the battery system For installation of connections and terminal plate assembly see Section 9 For installation of protective module cover see Section 10 1 TIE PLATE SEISMIC SHIM INSTALLED UNDER TIE PLATE WHERE APPLICABLE TIE PLATE BOTTOM MODULES Figure 20A M10 SERRATED FLANGE BOLT _ M10 SERRATED FLANGE NUT TIE PLATE TOP MODULES Figure 20B SECTION 9 9 0 Connections 9 1 Post Preparation Using either a brass bristle suede shoe brush or 3M Scotch Brite sc
11. InpusTRIAL POWER A Division of Exide Technologies
12. _ 15 M12 xX 40 BOLT 5 6 15 6 QUANTITY SHOWN IS FOR TERMINAL PLATE ASSEMBLY 000 am VLE iL 9 9 4 RR sassy NO MODULE CHANNELS N S SESS SES 2 2 4 MON 4 RANA SECTION PARTIAL RIGHT SIDE VIEW TERMINAL PLATE KIT 17 417003 Figure 23 TO ASSEMBLE THE ABSOLYTE GP MODULE COVER THE FOLLOWING ARE NEEDED ITEM UANTITY CLEAR COVER 1 STANDOFF LEG 4 4 CLOSEOUT 1 MODULE COVER ONLY TOP MODULE COVER CP PARTS SHOWN KEY KEY THREADS ARE INSERTED KEY IS PUSHED INTO THE 1 STANDOFF LEG INTO THE HOLE CHANNEL HOLE KEY SHANK TRAY CHANNEL IN THE CHANNEL KEEPS IT CENTERED STANDOFF LEG IS PARTIALLY LET GO OF THE KEY TURN KEEP TURNING THE LEG THREADED ONTO THE KEY LEG CLOCKWISE KEY WILL UNTIL IT TIGHTENS STILL TWO HANDS USED ROTATE UNTIL IT HITS DO NOT OVER TIGHTEN THE CHANNEL 7 INSTALL TOP CLOSEOUT ON TO INSTALL COVERS ONTO CLEAR COVER OF TOP MODULE STANDOFF LEGS CUT TO ALLOW FOR TERMINAL PLATE AS REQUIRED INSTALLATION GUIDE FOR ABSOLYTE GP MODULE COVER Figure 24 lt 9 8 Cell Numerals A set of pressure sensitive cell numerals and system polarity labels are supplied and should be applied at this time
13. concealed damage If damage is noted immediately request inspec tion by the carrier and file a concealed damage claim Pay particular attention to packing material exhibiting damage or electrolyte staining Delay in notifying carrier may result in loss of right to reimbursement for damages SECTION 4 4 0 Storage Prior to Installation 4 1 Storage Location If the battery is not to be installed at the time of receipt it is recommended that it be stored indoors in a cool 77 F 25 C or less clean dry location Do not stack pallets or cell termi nal damage may occur 4 2 Storage Interval storage interval from the date of battery shipment to date of installation and initial charge should not exceed six 6 months If extended storage is necessary the battery should be charged at regular intervals until installation can be completed and float charging can be initiated When in extended storage it is advised to mark the battery pallets with the date of shipment and the date of every charge If the battery is stored at 77 F 25 C or below the battery should be given a freshening charge perform per Section 11 Initial Charge within 6 months of the date of shipment and receive a freshening charge perform per Section 11 Initial Charge at 6 month intervals thereafter Storage at elevated temperatures will result in accelerated rates of self discharge For every 18 F 10 C temperature increase above 77 F 2
14. corrected 77 F 25 C Percent Float voltage per cell Reduction Minimum Maximum in Battery Life 2 23 2 27 090 2 28 2 32 50 2 33 2 37 75 Voltage records must be maintained by the user in accor dance with the maintanence schedule published in this manual To obtain the optimum service life from the battery it is impor tant to make sure the battery s float voltage is within the rec ommended range 127 Float Current and Thermal Management Increased float current can portend a condition known as thermal runaway where the battery produces more heat than it can dissipate VRLA batteries are more prone to thermal runaway because the recombination reaction that occurs at the negative plate and reduces water loss also produces heat High room temperature improper applications improper voltage settings and incorrect installation practices can increase the chances of thermal runaway As with good record keeping practices monitoring float current can prevent a minor excursion from becoming a major issue 12 8 AC Ripple AC ripple is noise or leftover AC waveform riding on the DC charge current to the battery that the rectifier did not remove It is usually more pronounced in UPS than telecom systems Proper maintenance of the UPS capacitors will reduce the amount of ripple going into the battery Establishment of absolute limits for AC ripple has always been problematic because the degree of damage it causes depends on the wave
15. of operation the battery is connected in parallel with a constant voltage charger and the critical load circuits The charger should be capable of maintaining the required constant voltage at battery terminals and also supply a nor mal connected load where applicable This sustains the bat tery in a fully charged condition and also makes it available to assume the emergency power requirements in the event of an AC power interruption or charger failure 12 2 Float Charge Float Voltages Following are the float voltage ranges recommended for the Absolyte Battery System Select any volts per cell VPC value within the range listed that will result in the series string having an average volts per cell equal to that value RECOMMENDED FLOAT RANGE 77 F 2 23 to 2 27 VPC NOTE Recommended float voltages are for 77 F For other temperatures a compensation factor of 003 V F 0055 V C per cell is recommended The minimum voltage is 2 20 VPC temperature correction does not apply below this voltage The maximum voltage is 2 35 VPC temperature correction does apply above this voltage 18 TEMPERATURE CORRECTION V corrected V25 C T actual 25 C x 0055V C or V corrected V77 F actual 77 F x 003V F See Appendix A for standard values Modern constant voltage output charging equipment is recom mended for the floating charger method of operation of GNB Absolyte batteries This type o
16. tions Every effort should be made to keep temperature varia tions within 5 F 38 C 5 4 Ventilation The Absolyte battery is a Valve Regulated Lead Acid VRLA low maintenance design Tests have confirmed that under recommended operating conditions in stationary applications 99 or more of gases generated are recombined within the cell In most cases no special ventilation and or battery room is required Consult your local building and fire codes for requirements that may apply to your specific location Hydrogen and oxygen gases can be vented to the atmosphere under certain conditions Therefore the battery should never be installed an air tight enclosure Sufficient precautions must be taken to prevent excessive overcharge 5 5 Floor Loading The floor of the area where the battery system is to be installed should have the capability of supporting the weight of the battery as well as any auxiliary equipment The total battery weight will depend on the cell size number of cells as well as module configuration involved Prior to installa tion a determination should be made that the floor integrity is adequate to accommodate the battery system 5 6 Floor Anchoring Where seismic conditions are anticipated floor anchoring must be implemented Where non seismic conditions are anticipated anchoring of hori zontally stacked systems is recommended for maximum stability Four 9 16 14 3 mm holes are provided in e
17. 222 222 7220 221 7220 221 ean APPENDIX B MAXIMUM STORAGE INTERVAL BETWEEN FRESHENING CHARGES VERSUS AVERAGE STORAGE TEMPERATURE Days N 2 jusiquy Maximum Storage Interval Months 25 65 Sa O 5 6 9 o N o N 9 9 3 2 APPENDIX C BONDING amp GROUNDING OF BATTERY RACK INTRODUCTION 1 To insure personnel safety and equipment protection operation and reliability the battery rack should be connected to the Common Bonding Network CBN 2 Electrical continuity between modules is provided through the use of serrated hardware If continuity between the horizontal supports and the bottom module is desired the use of a grounding kit GNB P N K17ABSGPGRND is required This kit is available through your local GNB representative GROUNDING KIT INSTALLATION 1 Each kit consists of the following components 2 6 AWG 12 in 90 C cables C shaped beam clamps 1 4 20 x 0 75 in bolts 1 4 20 x 1 00 in bolts 4 4 4 2 Using 1 1 4 20 x 1 00 in per beam clamp connect 1 beam clamp to the flange and 1 beam clamp to the back flange of the module see Figure 1 Be sure to securely tigh
18. 5 C the time interval for the initial freshening charge and subsequent freshening charges should be halved Thus if a battery is stored at 95 F 35 the maximum storage interval between charges would be 3 months reference Appendix B Storage beyond these periods without proper charge can result in excessive sulphation of plates and positive grid corrosion which is detrimental to battery performance and life Failure to charge accordingly may void the battery s warranty Initial and freshening charge data should be saved and included with the battery historical records see Section 15 Records SECTION 5 Installation Considerations AN Prior to starting installation of the Absolyte Battery System a review of this section is strongly recommended 5 0 Any modifications alterations or additions to an Absolyte system without the expressed written consent of GNB Engineering may void any warranties and or seismic qualifications Contact your GNB representative for additional information 5 1 It is important to know certain restrictions for the area where the battery is to be located First a designated aisle space should be provided to permit initial installation as well as for service or surveillance After installation any additional equip ment installed after the battery should not compromise access to the battery system Space Considerations A minimum aisle space of 36 inches from modules 33 inche
19. 6 MIN 33 MIN AISLE WAY MMMM LMM FIGURE 1B HORIZONTAL BACK TO BACK FIGURE 1 TYPICAL SYSTEMS TOP VIEW Annual Average Maximum Percent Battery Battery Reduction Temperature Temperature In Battery Life 77 25 122 50 0 86 F 30 122 50 30 95 35 122 50 50 104 40 122 50 66 113 45 122 50 75 122 50 122 50 83 For example If a battery has a design life of 20 years at 77 F 25 C but the actual annual average battery temperature is 95 F 35 C the projected service life of the battery is calcu lated to be only 10 years Temperature records shall be maintained by the user in accor dance with the maintanence schedule published in this manual The battery temperature shall not be allowed to exceed the maximum temperature shown above It is important to maintain the battery temperature as close to 77 F 25 C as possible to achieve the optimum service life from your battery 5 3 Temperature Variations Sources of heat or cooling directed on portions of the battery can cause temperature variations within the strings resulting in cell voltage differences and eventual compromise of battery performance Heat sources such as heaters sunlight or associated equipment can cause such temperature variations Similarly air condition ing or outside air vents may cause cell string temperature varia
20. An equalizing charge is a special charge given a battery when non uniformity in voltage has developed between cells It is given to restore all cells to a fully charged condition Use a charging voltage higher than the normal float voltage and for a specified number of hours as determined by the voltage used Non uniformity of cells may result from low float voltage due to improper adjustment of the charger or a panel voltmeter which reads an incorrect higher output voltage Also varia tions in cell temperatures greater than 5 F 2 78 C in the series string at a given time due to environmental conditions or module arrangement can cause low cells 13 1 Equalizing Frequency An equalizing charge should be given when the following con ditions exist A The float voltage of any cell as per Section 14 0 is less than 2 18 VPC B A recharge of the battery is required in a minimum time period following an emergency discharge C Individual cell s float is more than 0 05 volts from aver age D Accurate periodic records See Section 15 of individual cell voltages show an increase in spread since the previ ous semi annual readings An annual equalize charge is recommended to help ensure uniform cell performance 13 2 Equalizing Charge Method Constant voltage charging is the method for giving an equal izing charge Determine the maximum voltage that may be applied to the system equipment This voltage divided by th
21. C MARATHON LITHIUM POWER GNB Industrial Power a division of Exide Technologies is a global leader in network power applications including communication data networks UPS systems for computers and control systems electrical power generation and distribution systems as well as a wide range of other industrial standby power applications With strong manufacturing base in both North America and Europe and a truly global reach operations in more than 80 countries in sales and service GNB Industrial Power is best positioned to satisfy your back up power needs locally as well as all over the world GNB Industrial Power USA Tel 888 898 4462 Canada Tel 800 268 2698 www gnb com SECTION 92 61 2012 08 Sprinter Based on over 100 years of technological innovation the Network Power group leads the industry with the most recognized global brands such as ABSOLYTE FLOODED CLASSIC MARATHON ONYX RELAY GEL SONNENSCHEIN SPRINTER They have come symbolize quality reliability performance and excellence in all the markets served RELAY GEL Sonnenschein GNB Industrial Power takes pride in its commitment to a better environment Its Total Battery Management program an integrated approach to manufacturing distributing and recycling of lead acid batteries has been developed to ensure a safe and responsible life cycle for all of its products
22. Temperature Variations 4 5 4 E 4 2 2 Foor Load 4 5 6 4 5 7 Connecting Cables Battery System to Operating 4 5 7 1 NN 4 5 8 Slacking SIA ONNG 4 5 9 4 5 10 4 SECTION 6 6 0 Jnpacking and Handling E aaae D 5 6 1 e E A A A E E E E AE T 5 6 2 E eee E T EE ee ee 5 6 3 Recommended Installation Equipment and 5 6 4 e E E E meateoseewnesnaeant 5 6 5 AT E E T E AE E S E TS 5 SECTION 7 7 0 System Arrangements tc 6 7 1 6 7 2 Dummy Cells within a
23. ach support for anchoring To maintain seismic certification use four anchor bolts per horizontal support Anchor design is the responsibility of the purchaser installer 5 7 Connecting Cables Battery System to Operating Equipment The Absolyte cell is a UL recognized component Battery performance is based on the output at the battery terminals Therefore the shortest electrical connections between the battery system and the operating equipment results in maxi mum total system performance DO NOT SELECT CABLE SIZE BASED ON CURRENT CARRYING CAPACITY ONLY Cable size selection should provide no greater voltage drop between the battery system and operating equipment than necessary Excess voltage drop will reduce the desired support time of the battery system 5 7 1 Paralleling Where it is necessary to connect battery strings in parallel in order to obtain sufficient load backup time it is important to minimize the difference in voltage drop between the battery strings in parallel in order to promote equal load sharing upon discharge Therefore equal resistance of cable connections for each parallel string is important When paralleling multiple strings to a load or common bus please follow these guidelines e Each parallel string must have the same number of cells same string voltage cables connecting the positive and negative terminals of each string to the load or bus should be of the SAME SIZE i e
24. ays See Figures 15 16 and 17A G At this time check to see that the first two modules are plumb front to back and side to side using wooden or plastic level together with plywood straight edge This is to insure proper alignment for module interconnection later on Torque hardware to 47 Newton meters 35 Ft Lbs TIP OVER PROCEDURE MODULE WITH BASE ASSEMBLY Figure 12B AFTER TIP OVER Figure 13 NOTE 1 Straps must be criss crossed 2 Lifting shackle orientation and proper channel hole use must be observed 3 See Figure 4 for handling modules in vertical orientation 4 Lift single modules only HORIZONTAL STACKING SHACKLE STRAP USAGE Figure 14 9 H Proceed with stacking of remaining modules checking that stack is plumb in both axes as stacking progresses before torquing hardware Be certain to check the layout wiring diagram for correct horizontal orientation to provide proper polarity interconnection as stacking progresses See Figure 17B HANDLING AND STACKING HORIZONTAL MODULES Figure 15 M10 SERRATED 4 FLANGE BOLT M10 SERRATED FLANGE NUT HARDWARE INSTALLATION SEQUENCE Figure 16 INSTALLING HARDWARE Figure 17A 10 COMPLETED HORIZONTAL STACK Figure 17B 8 2 Horizontal Multiple Stacks It is recommended that all of the first modules with bottom supports attached see Section 8 1 1 be placed in position first A chalk line floor mark should be u
25. e number of cells connected in series will establish the maxi mum volts per cell that may be used to perform the equalizing charge in the shortest period of time not to exceed 2 35 VPC applicable at 77 F 25 C Refer to Table C for voltages and recommended time periods NOTE Charge volts listed in Table C are for 77 F For other temperatures a compensation factor of 003 V F 0055 V C per cell is recommended The minimum voltage is 2 20 VPC The maximum voltage is 2 35 VPC Temperature correction does not apply outside of this range V corrected V25 C T actual 25 C x 0055 V C or V corrected V77 F T actual 77 F x 003 V F See Appendix A for standard values STEP 1 A Set constant voltage charger to maximum setting without exceeding 2 35 VPC Example For a target charge of 2 35 VPC on a 24 cell system you would set the charger voltage to 56 4 volts B Record time and current at regular intervals every hour as aminimum C Continue charging the battery until there is no further drop in charge current over 3 consecutive hours D When the current has stabilized proceed to step 2 STEP 2 A Continue the charge for the time listed in Table C depending on the charger voltage setting The time is IN ADDITION to the time spent charging in Step 1 Example charge for 12 hours if the charger voltage is set to 2 35 VPC TABLE EQUALIZE CHARGE 77 F CELL VOLTS TIME HOURS 2 30
26. e safety valve may open and release these gases through the vent The gases can explode and cause blindness and other serious injury Keep sparks flames and smoking materials away from the battery area and the explosive gases All installation tools should be adequately insulated to minimize the possibility of shorting across connections DANGER ELECTRICAL SHOCK AND BURNS Never lay tools or other metallic objects on modules as shorting explosions and personal injury may result 2 3 Electrical Shock and Burns Multi cell systems attain high voltages therefore extreme caution must be exercised during installation of a battery sys tem to prevent serious electrical burns or shock Interrupt the AC and DC circuits before working on batteries or charging equipment Assure that personnel understand the risk of working with batteries and are prepared and equipped to take the nec essary safety precautions These installation and operating instructions should be understood and followed Assure that you have the necessary equipment for the work including insulated tools rubber gloves rubber aprons safety goggles and face protection N CAUTION If the foregoing precautions are not fully understood clarification should be obtained from your nearest GNB representative Local conditions may introduce situations not covered by GNB Safety Precautions 1 so contact the nearest GNB representative for guidance with you
27. ed TWO POST CELLS FOUR POST CELLS INTER MODULE CONNECTION INTER MODULE CONNECTION A B M6 STAINLESS STEEL BOLTS AND WASHERS SEE NOTE 2 TWO POST CELLS FOUR POST CELLS INTER STACK CONNECTION INTER STACK CONNECTION D Note 1 See Section 9 Connections 2 Torque hardware to 11 3 Newton meters 100 in lbs 3 Consult layout wiring diagram received with battery system 4 Curved edge of washer should face the connector VARIOUS INTER STACK AND INTER MODULE CONNECTIONS HORIZONTAL ARRANGEMENTS Figure 21 118 Two Hole Lug PART DESCRIPTION MATERIAL TERMINAL PLATE LEAD PL COPPER BOLT M12 30 STAINLESS STEEL WASHER FL 13 0 X 24 0 X 2 5 STAINLESS STEEL NUT M12 X STAINLESS STEEL Quantity shown is for terminal plate assembly TERMINAL PLATE KIT 6 CELL MODULES LOW RATE 3 HOURS OR LONGER BACK UP K17 417002 Figure 22 14 CABLE LUGS NOT SUPPLIED MODULE FRONT ITEM PART DESCRIPTION MATERIAL QTY 1 TERMINAL PLATE MOUNTING BRACKET POLYMER 1 22 BACKING PLATE SUPPORT PAINTED STEEL J 1 23 TRAY INSULATING SHIELD POLYMER 6 M6 FLAT WASHER 5 4 7 M6 NUT 2 8 40 BOT 2 55 2 9 8 350807 2 5 2 10 M8 2 FLAT WASHER 2 5 9 4 2211 M10 X 4 FLAT WASHER 5 4 42 M8 NUT 2 13 M10 LOCK WASHER 2 5 2 14 MIO JAM NUT 5 5 2
28. er Cell 2 26 2 27 2 23 2 30 2 29 2 29 2 29 2 28 2 28 2 28 2 28 2 27 2 27 2 27 2 26 2 20 2 26 2 25 2 25 2 25 2 25 2 24 2 24 2 24 2 23 2 23 2 23 2 22 2 22 2 22 2 22 2 21 2 21 2 21 2 20 2 20 3333 oo N NI on N 7 2 35 2 35 2 34 2 34 2 33 2 39 2 92 2 91 2 91 2 30 2 30 2 29 2 29 2 28 2 28 2 27 2 26 2 26 2 25 2 25 2 24 2 24 2 23 2 23 2 22 2 22 2 21 2 20 2 20 2 35 2 30 2 34 2 34 2 39 2 32 2 92 2 31 2 31 2 30 2 30 2 29 2 29 2 28 2 27 2 27 2 26 2 26 2 25 2 25 2 24 2 24 2 23 2 23 2 22 2 21 2 21 2 20 Battery Temperature F 24 Float Voltage at 77 F 2 24 2 25 2 26 2 27 230 231 232 2 33 2 30 231 232 233 2 32 2 32 2 32 2 32 2 31 2 31 2 91 2 30 2 30 2 30 2 29 2 29 2 29 2 29 2 28 2 28 2 28 2 27 2 27 2 27 2 26 2 26 2 26 2 26 2 25 2 25 2 25 2 24 2 24 2 24 2 23 2 23 2 20 2 23 2 22 2 22 2 22 2 27 29 230 29 2 30 2 30 2 30 28 2 29 228 229 250 228 229 228 2 28 2 28 227 7226 7225 226 7225 226 7224 225 3 24 225 2 24 225 7223 224 7223 224 7223 224 7223 224 225 7222 223 224 7222 223 224 7222 223 224 2 21 222 223 2 21 222 223 221 222 223 7220 221 222 7220 221 22 221
29. f charger properly adjusted to the recommended float voltages and following recommended lance procedures will assist in obtaining consistent serviceability and optimum life After the battery has been given its initial charge refer to Section 11 the charger should be adjusted to provide the recommended float voltages at the battery terminals Do not use float voltages higher or lower than those recom mended Reduced capacity or battery life will result Check and record battery terminal voltage on a regular basis Monthly checks are recommended See Section 15 0 Records second bullet If battery float voltage is above or below the correct value adjust charger to provide proper volt age as measured at the battery terminals 12 3 Voltmeter Calibration Panel and portable voltmeters used to indicate battery float voltages should be accurate at the operating voltage value The same holds true for portable meters used to read indi vidual cell voltages These meters should be checked against a standard every six months and calibrated when necessary 12 4 Recharge All batteries should be recharged as soon as possible follow ing a discharge with constant voltage chargers However to recharge in the shortest period of time raise the charger out put voltage to the highest value which the connected system will permit Do not exceed the voltages and times listed in Table C Section 13 2 12 5 Determining State of Cha
30. grease to the cleaned contact surfaces reinstall connectors and retorque connections to 11 3 Newton meters 100 inch pounds ALL TERMINAL AND INTERCELL CONNECTIONS SHOULD BE RETORQUED AT LEAST ONCE EVERY YEAR TO 11 3 NEWTON METERS 100 INCH POUNDS NOTE Design and or specifications subject to change without notice If questions arise contact your local sales representative for clarification SECTION 20 20 0 Capacity Testing When a capacity discharge test is desired it is recommended that it be performed in accordance with 1188 latest revision An equalizing charge as described in Section 13 2 must be completed within 7 days prior to the capacity test The bat teries must be returned to float charging immediately after the equalize charge completes Allow the batteries to float at least 72 hours prior to capacity discharge After the capacity discharge has completed the batteries can be recharged in the shortest amount of time by following the equalize charge procedure described in Section 13 2 1188 Recommended Practice for Maintenance Testing and Replacement of Valve Regulated Lead Acid VRLA Batteries for Stationary Applications ABSOLYTE BATTERY MAINTENANCE REPORT DATE PAGE 1 OF SERIAL NUMBER COMPANY ADDRESS GNB InpusTRIAL Power BATTERY LOCATION NUMBER A Division of Exide Technologies INSTALL DATE CHARGER VOLTAGE MANUF DATE TEMPERATURE TYPE i
31. hly prior to commissioning and strictly followed when working with Absolyte GP batteries CAUTION Before proceeding with the unpack ing handling installation and opera tion of this VRLA storage the following general information should be reviewed together with the recommended safety precautions SECTION 2 2 0 Safety Precautions 2 1 Sulfuric Acid Electrolyte Burns DANGER SULFURIC ACID ELECTROLYTE BURNS SULFURIC ACID CAN CAUSE BLINDNESS OR SEVERE BURNS Warning Risk of fire explosion or burns Do not disas semble heat above 50 C or incinerate Batteries contain dilute 1 310 nominal specific gravity sulfuric acid electrolyte which can cause burns and other serious injury In the event of contact with electrolyte flush immediately and thoroughly with water Secure medical attention immediately When working with batteries wear rubber apron and rubber gloves Wear safety goggles or other eye protection These will help prevent injury if contact is made with the acid WES DANGER i EXPLOSIVE GASES SMOKING 2 2 Explosive Gases Hydrogen gas formation is an inherent feature of all lead acid batteries Absolyte GP VRLA batteries however significantly reduce hydrogen formation Tests have shown that 99 or more of generated gases are recombined within the cell under normal operating conditions Under abnormal operating conditions e g charger malfunction th
32. hs if stored at 77 F Give the battery an equalizing charge as per Section 13 Following the equalizing charge open connections at the bat tery terminals to remove charger and load from the battery Repeat the above after every 6 months 77 F or at the required storage interval See Section 4 2 for adjustments to storage intervals when the storage temperature exceeds To return the battery to normal service re connect the battery to the charger and the load give an equalizing charge and return the battery to float operation SECTION 18 18 0 Unit Cleaning Periodically clean cell covers with a dry 2 paintbrush to remove accumulated dust If any cell parts appear to be damp with electrolyte or show signs of corrosion contact your local GNB representative CAUTION Do not clean plastic parts with solvents detergents oils mineral spirit or spray type cleaners as these may cause crazing or cracking of the plastic materials gt SECTION 19 19 0 Connections Battery terminals and intercell connections should be cor rosion free and tight for trouble free operation Periodically these connections should be inspected CAUTION DO NOT WORK ON CONNECTIONS WITH BATTERY CONNECTED TO CHARGER OR LOAD If corrosion is present disconnect the connector from the ter minal Gently clean the affected area using a suede brush or Scotch Brite scouring pad Apply a thin coating of NO OX ID A
33. imately equal to 2 15 volts times the number of cells in the system e g a 24 cell system would read 24 x 2 15v 51 6 volts 9 7 Connection Resistance Electrical integrity of connections can be objectively estab lished by measuring the resistance of each connection These resistances are typically in the microhm range Meters are available which determine connection resistance in microhms Be sure that the probes are touching only the posts to ensure that the contact resistance of connector to post is included in the reading Resistance measurements or microhm measurements should be taken at the time of installation and annually there after Initial measurements at installation become the bench mark values and should be recorded for future monitoring of electrical integrity It is important that the bench mark value for all similar con nections be no greater than 10 over the average If any connection resistance exceeds the average by more than 10 the connection should be remade so that an accept able bench mark value is established Bench mark values for connection resistances should also be established for terminal plates where used as well as cable connections Bench mark values should preferably be established upon installation All bench mark values should be recorded Annually all con nection resistances should be re measured Any connection which has a resistance value 20 above its benchmark value should be correct
34. ite scour pads f Hammer drill floor anchoring t Trademark of 6 4 Unpacking Carefully remove bolts and protective shipping hood See Figure 3 Remove the bolts holding modules to shipping pal let Also remove hardware bolting upper channels of modules together Do not remove modules at this time Base supports for horizontally stacked modules are more easily attached before removing modules from pallet see Section 8 0 System Assembly and Section 9 0 Connections Note Placement of modules on shipping pallet has no rela tionship to final installation UNPACKING MODULES Figure 3 AN The design of the modular tray permits handling by a fork lift portable crane or by a hoist sling see Figure 4 Whichever method is used make sure equipment can safely handle the module weight 6 5 Handling Always use the two lifting straps and four lifting shackles for lifting and placement of modules CAUTION If a fork lift or portable crane is used to handle modules in a horizontal position a piece of insulating mate rial such as heavy cardboard rubber insulating mats or plywood should be used between handling equipment and module tops to prevent shorting of module top connections with metal parts of lift equipment NOTE 1 Straps must be criss crossed 2 Lifting shackle orientation and proper channel hole use must be observed 3 See Figure 14 for handling modules in horizontal orientation 4 Never
35. lift more than two joined modules with straps and hooks HANDLING LIFTING STRAP PLACEMENT Figure 4 SECTION 7 7 0 System Arrangements 7 1 Module Arrangements Absolyte batteries are recommended for installation in a horizontal orientation only However vertical installation is approved for 50G systems consisting of single cell modules Figures 6 and 7 are typical arrangements and are not intend ed to represent all configuration possibilities Module stack height limitation depends on cell size and the seismic requirements of the application Please refer to Appendix D for additional information HORIZONTAL SINGLE STACK Figure 6A ff ff HORIZONTAL MULTIPLE STACKS END TO END Figure 6B HORIZONTAL SINGLE STACK BACK TO BACK Figure 6C HORIZONTAL MULTIPLE STACKS BACK TO BACK AND END TO END TYPICAL HORIZONTAL STACK ARRANGEMENTS Figure 7 7 2 Dummy Cells within a Module Where application voltage requires a dummy cell can replace a live cell in a module For example a 46 volt three cell per module system may consist of seven full modules and one module containing two live cells and either an empty space dummy cell SECTION 8 8 0 System Assembly 8 1 Horizontal Single Stack Consult layout wiring diagram for total number and type of module assemblies in system There can be varying combi nations of cell arrangements within the module May contain dummy cells depending on total s
36. ments Individual cell voltages Overall string voltage Ambient temperature immediately surrounding battery e Battery temperature at several places throughout the string Recommend 1 reading per battery stack More data points are recommended for larger batteries and to check for temperature gradients Readings on the tray cell cover or negative terminal are good places to measure battery temperature Take readings away from HVAC sources e Float current measured at stack to stack connections optional e Ohmic measurements optional Baseline ohmic readings of individual cells should be taken 6 months from the date of initial charge Retorque connectors as part of annual maintenance ONCE PER YEAR READINGS ARE THE ABSOLUTE MINIMUM REQUIRED TO PROTECT WARRANTY More frequent readings are recommended especially for critical sites Good record keeping will prevent minor issues from escalating into more serious problems over time See Figure 25 for sample record keeping form SECTION 16 16 0 Connections Tap connections should not be used on a battery This can Cause overcharging of the unused cells and undercharging of those cells supplying the load thus reducing battery life SECTION 17 17 0 Non Use An installed battery that is expected to stand idle longer than the maximum storage interval see Sec 4 2 should be treated as stated below The maximum storage interval is 6 mont
37. n Section 9 1 and brighten lead tin plated surfaces coming in contact with copper posts Apply a film of NO OX ID A grease to these areas NOTE Apply a minimum amount of grease to cover the surface As a rule If you can see it it s too much Where multiple connectors are required across any single connection brighten both sides of connectors along the entire length Grease these areas as well It is recommended when installing connec tors that the upper bolts be installed first to reduced risk of accidental shorting WASHERS SHOULD BE INSTALLED WITH THE CURVED EDGE TOWARD THE CONNECTORS POST BOLT WASHER CONNECTOR Cells are interconnected with connectors and hardware as shown in Figures 21A and 21B 9 4 Connections INTER Stack Multiple stacks end to end are interconnected as shown in Figure 21C and 21D Follow procedures in Section 9 1 and Section 9 3 Also see Section 9 5 Connections Torquing 9 5 Connections Torquing When all inter module connections have been installed tight en all connections to 11 3 Newton meters 100 in lbs Use insulated tools All connections should be rechecked after the initial charge due to heating during charge 9 6 Connection Check Again visually check to see that all module terminals are connected positive to negative throughout the battery Also measure the total voltage from terminal plate to terminal plate This should be approx
38. n of the transparent Module Covers Install standoff legs and standoff keys first as shown The cover is then installed by grasping it so that the GNB logo is upright Locate slots at the bottom of cover to the bottom standoff legs and slide in place Locate the holes at top of cover and install to top standoff legs Refer to Figure 24 SECTION 11 11 0 Initial Charge Batteries lose some charge during shipment as well as dur ing the period prior to installation A battery should be given its initial charge at installation Battery positive terminal should be connected to charger positive terminal and bat tery negative terminal to charger negative terminal Failure to perform the freshening charge within the limits stated in Section as well as failure to perform the initial charge upon installation of the battery 4 will affect the per formance and life of the battery and may void the warranty 11 1 Constant Voltage Method Constant voltage is the only charging method allowed Most modern chargers are of the constant voltage type Determine the maximum voltage that may be applied to the system equipment This voltage divided by the number of cells connected in series will establish the maximum volts per cell VPC that is available Table B lists recommended voltages and charge times for the initial charge Select the highest voltage the system allows to perform the initial charge in the shortest time period NOTE
39. ng the last 3 hours of the charge time If after the charge time has completed but the lowest cell voltage has continued to rise you may extend the charge monitoring cell voltages hourly until the lowest cell voltage ceases to rise 7 C Proceed to Step 3 STEP 3 The initial charge is complete Charger voltage can now be reduced to float voltage setting per Section 12 2 For a target float charge of 2 25 VPC on a 24 cell system you would set the charger voltage to 54 volts SECTION 12 12 0 Operation 12 0 1 Cycle Method of Operation In cycle operation the degree of discharge will vary for dif ferent applications Therefore the frequency of recharging and the amount of charge necessary will vary The amount of charge necessary depends on the number of ampere hours discharged Generally Absolyte GP cells require approximately 105 110 of the ampere hours removed to be returned to achieve a full state of charge The upper voltage settings recommended given that the maxium charge current is 5 of the nominal C100 Amp hour rating and ambient temperatures of 25 C 77 F are as fol lows 2 28 0 02 VPC 0 0 2 DOD 2 33 0 02 VPC 0 3 5 DOD 2 38 0 02 VPC 0 gt 5 DOD Due to the variety of applications and charging equipment particularly in Photovoltaic systems it is recommended that you contact an GNB representative when determining proper recharge profiles 12 1 Floating Charge Method In this type
40. ning Horizontal Base Modlule Horizontal Stacks Back to Back Positioning Completed Horizontal Stacks Side by Side Tie Plate Assemblies Horizontal Stacks Various Inter Stack and Intra Stack Connections Horizontal Arrangements Terminal Plate Kit 6 Cell Modules Terminal Plate Kit 3 Cell Modules Installation Guide for Absolyte GP Transparent Cover Absolyte Battery Maintenance Report APPENDICES Temperature Corrected Float Voltages Maximum Storage Interval Between Freshening Charges Versus Average Storage Temperature Bonding and Grounding of Battery Rack Absolyte GP Maximum Module Stack Heights SECTION 1 1 0 General Information The Absolyte GP battery is of the valve regulated lead acid VRLA design and so can operate with lower maintenance e g no maintenance water additions in comparison to conventional flooded lead acid batteries The Absolyte GP VRLA design is also inherently safer than conventional flooded lead acid batteries Under normal operating conditions and use the Absolyte GP battery minimizes hydrogen gas release and virtually eliminates acid misting and acid leakage However there is the possibility that under abnormal operating conditions e g over charge or as a result of damage misuse and or abuse potentially hazardous conditions hydrogen gassing acid misting and leakage may occur Thus GNB recommends that Section 2 0 of these instructions entitled SAFETY PRECAUTIONS be reviewed thoroug
41. ouring pad brighten the flat copper terminal surfaces to ensure lowest resistance connections Apply a thin film of NO OX ID A grease Supplied with bat tery to all terminal mating surfaces This will preclude oxida tion after connections are completed 9 2 Connections System Terminals Each system is supplied with a terminal plate assembly for the positive and negative terminations These should always be used to provide proper connection to the operating equipment and cell terminals Any attempt to connect load cables directly to cell terminals may compromise battery sys tem performance as well as the integrity of cell post seals For terminal plate assembly see Figure 22 6 cell modules at low rate or Figure 23 Consult layout wiring diagram for proper kit use It is recommended that all components be assembled in place with hardware torqued to 11 3 Newton meters 100 in lbs Retorque value is also 11 3 Newton meters 100 in lbs Refer to Sections 9 1 and 9 3 for electrical contact surface preparation of terminal plate components As shown terminal plate assembly can be varied to satisfy module terminal location as well as orientation of terminal plate in a horizontal or vertical plane Do not make connec tions to operating system at this time 9 3 Connections INTER Module Consult layout wiring diagram for correct quantity of lead tin plated copper connectors required at each connection Follow procedure i
42. r particular safety prob lem also refer to applicable federal state and local regulations as well as industry standards 2 3 1 Static Discharge Precautions for Batteries When maintaining the batteries care must be taken to prevent build up of static charge This danger is particularly significant when the worker is electrically isolated i e working on a rub ber mat or an epoxy painted floor or wearing rubber shoes Prior to making contact with the cell discharge static electric ity by touching a grounded surface Wearing a ground strap while working on a connected battery string is not recommended 2 4 Safety Alert The safety alert symbol on the left appears throughout this manual Where the symbol appears obey the safety message to avoid personal injury 2 5 Important Message The symbol on the left indicates an impor tant message If not followed damage to and or impaired performance of the battery may result SECTION 3 3 0 Receipt of Shipment Immediately upon delivery examine for possible damage caused in transit Damaged packing material or staining from leaking electrolyte could indicate rough handling Make a descriptive notation on the delivery receipt before signing Look for evidence of top loading or dents in the steel mod ules If cell or unit damage is found request an inspection by the carrier and file a damage claim 3 1 Concealed Damage Within 10 days of receipt examine all cells for
43. rge If the normal connected load is constant no emergency load connected the following method can be used to determine the approximate state of charge of the battery The state of charge can be identified to some degree by the amount of charging current going to the battery When initially placed on charge or recharge following a discharge the charging current read at the charger ammeter will be a combination of the load current plus the current necessary to charge the battery The current to the battery will start to decrease and will finally stabilize when the battery becomes fully charged If the current level remains constant for three consecutive hours then this reflects a state of charge of approximately 95 to 98 For most requirements the battery is ready for use If the normal connected load is variable i e telecommunica tions the following method may be used to check the state of charge of the battery Measure the voltage across a pilot cell See Section 14 0 for definition of pilot cell If the voltage is stable for 24 consecutive hours the battery reflects a state of charge of approximately 95 12 6 Effects of Float Voltage Float voltage has a direct effect on the service life of your battery and can be the cause of thermal instability A float voltage above the recommended values reduces ser vice life The chart below shows the effects of float voltage temperature corrected on battery life Temperature
44. s from covers should be available adjacent to the battery sys tem See Figure 1 for typical space allocations required Following the spacing requirements will aid in maintenance of the battery and help maintain air flow to battery surfaces to enhance heat dissipation NOTE When planning system space requirements allow at least 6 inches past system total length wherever a terminal plate assembly is to be located See Figure 1A Figure 1 A B are typical For total length width and height dimensions of connected systems consult layout wiring dia gram for the particular system 5 2 Battery Location amp Ambient Temperature Requirements It is recommended that the battery unit be installed in a clean cool dry location Floors should be level Absolyte batteries can be installed in proximity to electronic equipment A location having an ambient temperature of 75 F 24 C to 77 F 25 C will result in optimum battery life and perfor mance Temperatures below 77 F 25 C reduce battery charge efficiency and discharge performance Temperatures above 77 F 25 C will result in a reduction in battery life see table below 27772 4 5 MINIMUM FOR EASE OF ASSEMBLY AND COOLING 36 MIN 33 MIN AISLE WAY IMM MUL gt FIGURE 1A HORIZONTAL END TO END MIM MMMM MULL LLL MMM MAMAN 36 MIN 33 MIN AISLE WAY FRONT OF MODULE 4 5 MINIMUM FOR EASE OF ASSEMBLY AND COOLING 3
45. s parallel VRLA battery configurations as the feedback signal to the device may follow unforeseen paths that can overwhelm it It is best for users to establish their own baseline values for their battery as specifically configured Do not rely on reference values If users wish to enhance normal maintenance and record keeping with ohmic measurements GNB recommends the trending of this data over time Use a first set of readings taken 6 months after initial charge and installation as the baseline data Subsequent measurements should be taken using the same device over the life of the battery Because cell positioning within the string connector configuration to a particular cell can affect the reading always compare each cell at baseline to itself in the new data Standalone ohmic data is not sufficient to justify warranty cell replacement Responsible ohmic device manufacturers acknowledge that there is no direct relationship between percent ohmic change from baseline and battery capacity A change from baseline of 25 or less is in the normal noise or variability range Changes between 25 and 50 may call for additional scrutiny of the system An IEEE compliant discharge test is usually warranted on systems exhibiting more than a 50 change from baseline Consult an GNB representative for specific questions about ohmic data SECTION 13 13 0 Equalizing Charge Under normal operating conditions an equalizing charge is not required
46. sed to assure all stacks will be in a straight line This applies for stacks end to end or end to end and back to back Also refer to Section 8 1 3 Items A through H for base module leveling Module ends should be butted together so that module side channel ends meet see Figure 18 Refer to layout wiring diagram for seismic shim requirements At this time stack tie plates should be installed see Section 8 2 1 It will be necessary to temporarily remove the hard ware fastening the base modules to the I beams See Figure 20A Install tie plates and hardware Torque to 47 Newton meters 35 Ft Lbs For stacks back to back the two base modules are posi tioned to provide a minimum 4 5 spacing between the bot toms of the modules not I beam edges See Figure 19A When all base modules are set in place continue with stack ing of subsequent modules Procedures for assembly of multiple horizontal stacks are the same as outlined in section 9 1 Also consult layout wiring diagram Each stack should be built up in sequence to the same level until the top modules in all stacks are the last to be installed The use of a line cord attached to upper module corners of opposite end modules as stacking progresses aids in alignment See Figure 19B Note 1 Level moduies beneath both axes to achieve proper Interfacing of channei ends and installation Inter stack connectors POSITIONING HORIZONTAL
47. shape peak to peak magnitude and frequency Accurate characterization of AC ripple requires an oscilloscope and even then only represents a picture of the ripple at that moment in time Whatever its exact characteristics AC ripple is always harmful to batteries Depending on its particular properties ripple can result in overcharge undercharge and micro cycling that can prematurely age the battery The most common and damaging result of AC ripple is battery heating which can lead to thermal runaway AC ripple will decrease battery life and should be reduced as much as possible 12 9 Ohmic Measurements Impedance resistance and conductance testing is collectively known in the industry as ohmic measurements Each measurement is derived using a manufacturer specific and proprietary algorithm and or frequency This means that one type of measurement cannot be converted or related easily to another 19 Reference ohmic values are of dubious value because so many factors can affect the way the readings are made and displayed by the devices Connector configuration and AC ripple as well as differences between readings of temperature and probe placement will prevent the ohmic devices from generating consistent and meaningful data The meters work better with monoblocs and small capacity VRLA products and less well with large gt 800 Ah VRLA and flooded battery designs Users should be particularly skeptical of data taken on serie
48. ten the bolts such that the paint is penetrated see Figure 2 3 Attach each end of cable assembly to a beam clamp using 1 1 4 20 x 0 75 in bolt per end see Figure 3 Tighten hardware securely 4 Repeat Steps 2 and for the second horizontal support l beam Figure 1 Beam Clamp Installation Figure 2 Adequate Paint Penetration Figure 3 Cable Assembly Installation CONNECTING TO THE CBN 1 The recommended location for attaching the frame ground is the back C channel on the upper module of the stack see Figure 4 Figure 4 Recommended Frame Ground Location 2 Once the location is determined it will be necessary to drill 2 holes for the frame ground conductor lug installer supplied Note hole size and spacing will be dependent on the lug 3 Using grinder etc remove the paint from around the holes drilled in Step 2 Apply a thin film of NO OX ID A grease to the bare metal and attach the frame ground conductor lug 26 APPENDIX D Absolyte GP Maximum Module Stack Heights Horizontal Arrangement Series Height 1 28 3 4 _ 100G 10 high 100633 100633 100631 100617 9 high 100633 100633 100633 100623 90G 10high 90615 90615 90G15 90G09 _ 9 90615 90G15 90G15 90 11 50G 10high 50G09 50G09 50G09 50G09 9 high 50G11 50611 50G11 50G11 50G15 50G15 50G15 50G15 GNB Industrial Power The Industry Leader GNB Flooded m ABS LYTE 7ZlaSSi
49. teria Similarly install the remaining I beam support on the other side of the module see Figure 10 M10 WEDGE WASHER 1 M10 LOCK WASHER M10 NUT cip HARDWARE INSTALLATION FOR 2 67 WIDE I BEAM SUPPORT Figure 8 ACCESS 51075 M10 4 N LOCK WASHER 24 2 SUPPORT WASHER __ SEISMIC SHM Wacuen M10 BOLT HARDWARE INSTALLATION FOR 4 5 WIDE I BEAM SUPPORT Figure 9 COMPLETED I BEAM SUPPORT TO MODULE INSTALLATION Figure 10 8 1 2 Handling The module base support assembly may now be removed from the pallet using methods outlined in section 6 5 Handling Also see Figure 11 Remaining modules may be removed in a similar manner 8 1 3 Horizontal Stacking In order to stack modules in the horizontal position refer to Figures 11 thru 13 to perform the tip over procedure The module base support assembly tip over should be performed first This procedure can be performed using a portable boom crane or fork lift in conjunction with the lifting straps and lifting shackles supplied CAUTION DO NOT ATTEMPT TO PERFORM TIP OVER OF MODULE MANUALLY AS SERIOUS PERSONAL INJURY AND MODULE DAMAGE MAY RESULT A Install lifting strap using lifting shackles in channel base holes at each end of module upper rear channel as shown in Figure 12A B Center the lifting hook onto strap and lift until strap is under tension and raises bottom of module from floor surface so
50. that upper and lower diagonal corners are ina vertical mode C While exerting manual force on the upper rear of module lower hoist until module is in horizontal position See Figures 12B and 13 D When module is horizontal install the four lifting shackles and two lifting straps as shown in Figure 14 HANDLING MODULE BASE SUPPORT ASSEMBLY Figure 11 E Where floor anchoring is required position module base assembly in desired location Mark floor through I beam holes and remove module base assembly Install floor anchoring and reposition module base assembly over anchoring Prior to installing nuts and washers check that assembly is level in both axes Level using shims pro vided Torque anchor hardware to manufacturer s recom mended value UPPER REAR CHANNEL FLOOR LINE FLOOR LINE NOTE 1 strap with shackles used for tip over 2 Observe channel hole used well as direction of shackle insertion 3 Tip over procedure for single modules only TIP OVER PROCEDURE SHACKLE STRAP USAGE Figure 12A F Using Steps A D and the layout wiring diagram position the next module on top of first so that channels of each mate with one another using drift pins to align channel holes Make sure channel ends and sides of the upper and lower modules are flush Install serrated flange bolts and nuts in open holes finger tight Remove lifting straps Use leveling shims to fill gaps between tr
51. the top adjacent channels See Figure 2 6 2 Accessories Accessories are packed separately and will include the following Note Some items may not be provided depending on battery configuration e Layout wiring diagram Installation and operating instructions Lifting straps and lifting shackles e Protective covers and hardware Terminal plate assembly kits and covers e Module tie plates where required i e side by side stacks Vertical or horizontal supports e Lead Tin Plated copper intercell connectors Assembly hardware NO OX ID grease Battery warning label e Battery nameplate Cell numerals with polarity indicators e Shims leveling Drift pins e Seismic Shims where required Included with systems containing stacks of 7 or more modules in height Registered Trademark of Sanchem Inc NOTE Check battery components against supplied drawings to assure completeness Do not proceed with installation until all accessory parts are available 6 3 Recommended Installation Equipment and Supplies Fork lift or portable boom crane e Chalk line e Line Cord Torpedo level Plastic Plywood straight edge 1 2 x 4 x 48 e Torque wrenches e Ratchet wrench with 10 13 17 19 mm sockets and 2 and 15 mm deep sockets Box wrenches of 10 13 15 17 19 mm sizes Vinyl electrical tape e Paper wipers e Scotch Br
52. ystem voltage Compare required module assemblies called for on layout wiring diagram with modules in shipment for completeness before continuing further 8 1 1 Bottom Supports Locate bottom I beam supports and M10 I beam hardware kit I beam supports and seismic shims should be attached to the appropriate module assembly shown on the layout wiring diagram prior to removal from shipping pallet NOTE Seismic shims will be supplied with systems for which they are required to maintain seismic compliance Secure I beam support to a module channel as shown in supplied drawing with access slots outward Please refer to Figure 8 and 9 for general hardware installation information Seismic shims when supplied are placed between the channel and the nut and oriented 50 as to not extend beyond the end of the channel Torque hard ware to 47 Newton meters 35 ft lbs using insulated tools When correctly attached the I beam support will be flush with the front module channel and approximately 13mm 0 50 away from the back of the module The side of the I beam support will be approxi mately 10mm 0 38 away from the end of the channels NOTE The use of leveling shims is required when assembling any Absolyte system in order to meet seismic requirements Failure to use the shims to level each module and to fill spac es between tray channels during module assembly will result in the assembly not meeting seismic certification cri
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